Composite plaster base and insulating unit



Dec. 27, 1938. c, R. PEMBERTON COMPOSITE PLASTER BASE AND INSULATINGUNIT Filed June l5, 1938 2 Sheets-Sheet l Dec. 27, 1938. c. R. PEMBRTONCOMPOSITE PLASTER BSE AND INSULATING UIT Filed June 15, 195s 2Sheets-Sheet 2- Patented Dec. 27, 1938 UNITED STATES PATENT OFFICE 1"Cecil n. Pemberton, silver spring, Md.

Application June 15, 1938, Serial No. 213,919

11 Claims.

The present invention relates to a composite plaster base and insulatingunit for buildingconstruction.

It is an object of the invention to provide a composite plaster base andinsulating unit embodying a rigid plaster supporting base and insulatingmaterial permanently attached, to the base so that the same may beapplied directly to studding or other spaced Supporting members, such asfurring strips, roof rafters etc. in a single operation, therebyeliminating the separate handling and installation of insulatingmaterial and lathing in the building operation.

' Another object is to provide a composite plaster 5 base and insulatingunit in which a rigid base member of novel construction is provided onone side with a plaster receiving surface and on the other side withinsulating elements which are supported solely by the base in such amanner as to be wholly disposed between adjacent studding or othersupporting elementswhen the unit isv installed.

Another object of the invention is to provide a composite plaster baseand insulating unit in which the insulating material is effectivelysupported over its entire surface area so that it is prevented frompacking down after installation in vertical walls and is also protectedagainst moisture.

0 For a better understanding of the invention, reference is made to theaccompanying drawings which illustrate preferred embodiments thereof andin which,

Fig. 1 is a sectional perspective view of the front 5 face of a portionof a building wall embodying the invention, y

Fig. 2 is a sectional perspective view of the back of the unit shown inFig. l,

Fig. 3 is a front elevation of a wall embodying the invention, withparts broken away,

Fig. 4 is a sectional 'view on the line 4,-4 of Fig. 3,

Fig. 5 is a sectional view on the line 5-5 of Fig. 3,

,5 Fig. 6 is a sectional view on the line 6-6 of Fig.v 5, y

Fig. 7 is a sectional perspective view of aportion of a wall embodying amodified yform of the invention, and

I0 Fig. 8 is a sectional perspective view of a pox'-a tion of a wallembodying a further modification.

The form of the invention illustrated in Figs. 1 to 6 inclusive will bedescribed rst. The supporting members I0 which will be referred to as i5studs for convenience may be furrng strips, raft- .units embodying theinvention will be made in sizes and the elements thereof dimensioned forapplication to supports placed on all standard centers.

The base sheet or panel Il forming a part of 10 the invention issubstantially the same in all forms. Y

The base panel II may be of different lengths depending on the spacingbetween the studding members but in each size classification ispreferably long enough to span the intervening spaces between at leastthree studs. The unit of-Fig. 1 is shown as spanning the spaces betweenfour studs, the ends terminating on the center of the studs at each endof .the unita The base panel `consists of a plurality of lath members I2maintained in spaced parallel rela'- tion and extending lengthwise ofthe panel and coextensive therewith. The lath members, which may beordinary wood lath or composition strips formed of -cement plaster andasbestos, are secured between a facing sheet I3 and a backing sheet I4of fibrous material such as paper felt. Each of thesesheets is providedon its inside face with a coating I5 of asphalt or similar seal- 30;

ing and adhesive material which serves to secure the laths and sheetstogether as a unit and also seals the panel against the passage of airor moisture therethrough. In making the unit, the asphalt is applied hotto one surface of each sheet and the lath is placed in position on thecoated surface of one sheet and the other sheet is then applied with itscoated surface against the lathing strips, thereby forming an integrallunit.

The facing sheet I3 is provided with a plurality of small openings I6uniformly spaced over the area of the panel. These openings coincidewith the spaces I1 betweenthe lathing strips and allow the entry of apart of the plaster I9 applied 45 to the face so as to form interlockingplaster keys I8. It will be noted from an inspection of Figs. 4, 5 and 6that the plaster keys will ll the cross sectional area of the spaces I1between the laths, thereby forming sealing stops which divide the spacesI1 into a plurality of dead air cells, thus contributing to theinsulating efdciency of the unit.

A pluralityy of pads or batts 20 of insulating wool materiaLvwhich maybe any commercial fibrous or Wool-like material, such as Balsam wool orthe like, are adhesively secured to the outer face of the backing sheetI4 in spaced relation, each -pad covering the area of the panel whichwill lie vbetween studs when the unit is in position so that the rearface of the panel is left clear along the lines of contact with thestudding.

By mounting the insulating pads on the panel in spaced relation asdescribed, it will be observed that the plane rear face of the panelmakes direct contact with the studs so that the front faces of thepanels will be flush with each other. This is considered importantbecause if the panels were nailed to the studding with intervening lay-lers of insulating material, the resulting wall surface would be unevendue to the variation in the compression of the intervening insulation innailing the units in place.

The insulating pads or batts are secured to the rear face of the panelsI I by means of a layer of hot asphalt 2I applied to the backing sheetI4 before the insulation is applied thereto. In order to protect, andadditionally support the insulation and increase the water resistantproperties of the entire unit, each` pad or batt of insulating materialis` enclosed by a wrapping of waterproofed crepe paper 22. The crepepaper is adhesively secured to the batt by means of hot asphalt and thesides are turned inwardly around and under the edge of the bats asindicated at 23 and secured directly to the panel II by means of theasphalt layer 2|. The ends of the paper covering are also turnedinwardly and similarly secured as seen at 24.

The insulating batts are thus seen to be entirely enclosed in a waterproof covering and are supported on all sides so that there ls no DOSSI-bility of the insulation packing down after installation. i

In order to increase the rigidity of the units and to prevent bending orrolling of the same in handling before installation, a plurality oflaths or strips 25 are cemented to the rear face of the panel II at,right angles to the laths I2. These strips are preferably disposedcentrally of the area covered by the insulation pads 20. While the hotasphalt used in securing the pads to the backing sheet forms aneiiicient means of attaching the reinforcing strips in position, theymay be additionally secured to the laths I2 by suitable metallic clipsor nails, if desired.

The ends of the composite panels II are iinished by applying an adhesivebinding tape 26 over the edges. This tape serves to seal the ends of thespaces I1 between the laths and also adds to the nished appearance ofthe unit as a whole.

In applying the units in the fabrication of a wall, the complete unit isplaced in position in one operation with the individual envelopes orpads of insulation sliding into position in the spaces betweenadjacentstuds and theexposed areas of the backing sheet I5 of the panel Ildirectly engaging the faces of the studding. The units are then securedin position by nails 21 driven through the panels into the studding.

It will be noted that the clear space on the back of the panels betweenthe ends and the adjacent pads is equal to half the thickness of a studso that the units can be mounted with their ends in abutting relationand centered on the studs.

In the modied form of the invention shown in Fig. '1, the panel II is ofthe same construction as described above. In this embodiment, the crepepaper wrapping or envelope 3l completely encloses the insulating pad 3l,extending around to the back of the pad and having its edges lapped overand sealed as at 32. 'I'he ends of the crepe paper wrapping are likewiseturned inwardly to seal the upper and lower ends of the insulating padas at 33. Before the insulating material is enclosed in the paperwrapping, the latter is coated with hot asphalt or the like so as towater proof the same and so that the insulation will be secured to theWrapping on all surj faces.

A plurality of the complete envelopes are secured to the rear face ofthe panel I I by means of a hot asphalt layer 34, leaving a spacebetween adjacent envelopes suiicient to receive the studj ding or otherspaced supporting members upon which the unit is to be mounted.

A reinforcing transversely extending lath or strip 35 is mounted on therear face of the panel centrally of each of the envelopes of insulating1 In this way, the strip would be directly cemented to the panel atspaced Aintervals and would aid in securing the envelope to the panel aswell as serving r4to' strengthen the unit against bending or rolling.

In the form of the invention shown in Fig. 8, the insulation which isfitted between the studdings is omitted. This unit may be used whereless insulation is required and where an emcient plaster base is theprimary objective. This unit also is similar to the panel II, consistingof backing and facing sheets 36 and interposed spaced parallel laths 38,the whole being secured together by asphalt layers 39 applied to theinner faces of the sheets 36 and 31. A reinforcing strip 40 applied tothe rear face of the backing sheet 36 may be provided or in some casesmay be omitted if desired.v 'I'he facing sheet is provided with openings4I opening into the spaces between the laths 38 to form plasterinterlocking keys as described above.

It will be seen from the above that the invention provides a very strongdurable andl rigid plaster base or wall surfacing member havinginsulating properties, and also insulation in the form of the padscarried on the back of the panels which pads will engage adjacent studsalong the l sides and will Iengage the ends of the pads of adjacentunits when a plurality of units are mounted together in making up a wallso that a continuous blanket of insulation will be provided.

While preferred embodiments of the invention have been illustrated anddescribed by way of example, it will be understood that various othermodifications and changes in the details may be resorted to withoutdeparting fromthe spirit of the invention as dened in the claims.

. I claim:

1. In a composite unit adapted for direct application to spacedsupporting elements to form an insulated wall having a surface suitablefor the reception of a plaster coat, a rigid panel member comprising aplurality of lath members disposed in spaced parallel relation and of alength to bridge a plurality of said spaced supporting elements, afacing sheet and a backing sheet of fibrous material adhesively unitedto the opposite faces of said lath members to maintain the latter inspaced relation and form air cells therebetween, and a plurality'ofindividual insulating pad members adhesively secured to one face of saidunit in spaced relation, said insulating pad i members beingsubstantially equal in width to the space between the supportingelements to which the unit is to be applied and spaced apart a distancesubstantially equal to the width of saidy elements.

, 2. In a composite unit adapted for direct application to spacedsupporting elements to form an insulated wall having a surface suitablefor the reception of a plaster coat, a rigid panel memberxcomprising aplurality of lath members disposed in spaced parallel relation and of alength to bridge a plurality of said spaced supporting elements, afacing sheet and a backing sheet of fibrous material adhesively unitedto the opposite faces of said lath members to maintain the latter inspaced relation'and form air cells therebef tween, said facing sheethaving a plurality of openings therein coinciding with the spacesbetween said lath members, for admitting plaster applied to said facingsheet into the interspaces between said laths toform interlocking keysand divide said interspaces into separate closed air cells- 3. In acomposite unit adapted for direct application to spaped supportingelements to form an insulated wall having a surface suitable for thereception of a plaster coat, a rigid panel mem ber comprising aplurality of lath members disposed in spaced parallel relation and of alength to bridge a plurality of said spaced supporting elements, afacing sheet and a backing sheet of fibrous material adhesively unitedto the opposite faces of said lath members to maintain the latter inspaced relation and form air cells therebe. tween, said facing sheethaving a plurality of openings therein coinciding with the spaces be;tween said lath members, for admitting plastr applied to said facingsheet into `the interspaces between said laths to form interlocking keysand divide said interspaces into separate closed air cells, and aplurality of individual insulating pad members adhesively secured to oneface of said unit in spaced relation: said insulating pad members beingsubstantially equal in width to the distance between the supportingelements to which the unit is to be applied and spaced apart a distancesubstantially equal to the width of said elements. f

4. In a composite unit adapted for direct application to spacedsupporting elements to form an insulated wall having a surface suitablefor i the reception of a plaster coat, a rigid panel member lcomprisinga plurality. of lath members disposed in spaced parallel relation and ofa length to bridge a plurality of said spaced supporting elements, afacing sheet and a backing sheet of brous material adhesively united tothe opposite faces of said lath members to maintain the latter in spacedrelation and form air cells therebetween, and a plurality of individualinsulating pad members adhesively secured to one face of said unit inspaced relation, said insulating pad members beingsubstantially-equal'in Width to the distance between the supportingLelements to which the unit is to be applied and spaced apart a distancesubstantially equal to the width of said elements, and a lathing stripsecured to the backing sheet insideof said insulating pad members andextending cross-wise 'of the lathing members between said sheets.

5. A composite plaster base and heat insulating material adapted fordirect application to wall studding members or the like as a unit whichcomprises, a rigid panel member comprising a facing of fibrous materialand a backing sheet of entrance of plaster applied to said face to form6. In a composite unit adapted for direct application to spacedsupporting elements to form an insulated wall having a surface suitablefor the reception of a plaster coat, a rigid panel member comprising aplurality of lath members disposed in spaced parallel relation and of alength to bridge a plurality of said spaced supporting` elements, afacing sheet and a backing sheet of fibrous material adhesively unitedto the opposite faces of said lath members to maintain the latter inspaced relation and form air cells therebetween, said facing sheethaving a plurality of openings therein coinciding with the spacesbetween said lath membersfor admitting plaster applied to said facingsheet into the interspaces between said laths to form interlocking keysand divide said interspaces into separate closed air cells, a pluralityof insulating pad members secured to said backing sheet in spacedrelation to each other, saidpad members each comprisinga looselyfeltedsheet of fibrous in sulating material, said insulating pad membersbeingsubstantially equal vin width to the spaces between the supportingbuilding elements to which the unit is to be applied, and spaced apart adistance equal to the width of said elements.

7. In a composite unit adapted for direct application to spacesupporting elements to form an insulated wall having a' surface suitablefor the reception of a plaster coat, a rigid panel member comprising aplurality of lath members disposed in spaced parallel relation and of alength to bridge a plurality of said spaced supporting elements, afacing sheet and a backing sheet of fibrous material' adhestvely unitedto the opposite faces of said lath members'to maintain the latter inspaced relation an form air cells therebetween, said facing sheet avinga plurality of openings therein coinci ng with the spaces between saidlath members, for admitting face of said panel, said insulating padmembers I being substantially equal in width to the spaces between thesupporting building elements to which the unit is to be applied, landspaced apart a distance equal to the width of said elements.

8. In a composite unit adapted for direct appliction to spacedsupporting elements to form an insulated wall having a surface suitablefor the reception of a plastercoat, a rigid panel member comprising aplurality of lath members disposed in spaced parallel relation and of alength to bridge a plurality of said spaced supporting members, a facingsheet and a backing sheet of fibrous material adhesively united to theopposite faces ofsaid lath members to maintain the latter in spacedrelation and form air cells therebetween, means for sealing the ends ofsaid r plication to spaced supporting elements to form i an insulatedwall having a surface suitable for the reception of a plastercoat, arigid panel member comprising a plurality of lath members disposed inspaced parallel relation and of a length to bridge a plurality of saidspaced supporting members, a facing sheet and a backing sheet of brousmaterial adhesively united to the opposite faces of said lath members tomaintain the latter in spaced relation and form air cells therebetweensaid facing sheet having a 'plurality of openings therein coincidingwith the spaces between said lath members, for admitting plaster appliedto said facing sheet into the interspaces between said laths to forminterlocking keys and divide said interspaces into separate closed aircells and means for sealing the ends of said air cells at the ends ofsaid panel comprising a ilexible strip extendingover the edge thereofand /adhesively secured to the .facing and backing sheets. 1

10. In a composite unit adapted for direct application to spacedsupporting elements to form an insulated wall having a surface suitablefor the reception of a plaster coat, a rigid panel member comprising aplurality of lath# members disposedl in spaced parallel relation and ofa Alength to bridge a plurality of said spaced supporting members, afacing sheet and a backing sheet of brous material adhered to the oppo-Vsite faces of said lath members to maintain the latter in spacedrelation and form air cells therebetween, one of said sheets having acoating of waterproofing material covering one face thereof, said facingsheet having a pluralityof openings therein coinciding with the spacesbetween said lath members, for admitting plaster applied to said facingsheet into the interspaces between said lath members to forminterlocking keys and divide said interspaces into separate closed aircells.

v11. In a composite unit adapted for direct application to spacedsupporting elements to form an insulated wall having a surface suitablefor the reception of a plaster coat, a rigid panel member comprising aplurality of composition strips disposed in spaced parallel relation andof a length `to bridge a plurality of said spaced supporting elements, afacing sheet and a backing sheet of fibrous material adhered to the opposite faces of said composition strips to mainf tain the latter inspaced parallel relation and form air cells therebetween, said facingsheet having a plurality of openings therein coinciding with the spacesbetween said composition strips for admitting plaster applied to saidfacing

